Primary cell and battery



Allg. 12, 1952 S RUBEN 2,606,941

FRIMARY CELL AND BATTERY Filed May 21, 194e 2 SHEETS-SHEET 1 ZW@ JZ 44 INVEN-roR dmnue/ an BMZ@ ATTORNEY PRIMARY CELL AND BATTERY Filed May 2l, 1946 2 SI-IEETS-SI-IEET 2 l l INVENTOR cfamuel juen ATTORNEY Patented ug. l2,

vUNI'IED STATES PATENT OFFICE PRIMARY CELL AND BATTERY y samuel Rben, New Rochelle, N. Y. Application May 21, 194e,seria1lNo. 671,200 s claims. (ci. 13e-in) This invention relates to alkaline dry cells and batteries.

The present application is a continuation-inpart of my prior filed co-pending applications, Serial No. 601,626, led June 26, 1945 (U. S. Letters Patent 2,458,878), and Serial No. 604,269,

iled July 10, 1945 (U. S. Letters Patent 2,422,045)

andSerial No. 631,402, Afiled November r248, 1945 (U. S. Letters Patent 2,536,696).

An object of the invention is to provide improved `structures for dry cells and batteries.v

' Other objects will be apparentl from the following description and claims;

The present invention contemplates a sealed dry cell'of novel construction. A'feature of the invention resides in the construction of a at type cell in which the electrolyte may be immobilized by absorbent spacers or bygellig Further features will be apparent from the following description and the claims.

In the drawings:

Figure 1 is a sectional view of a hat dry cell embodying features of the .present invention;

Figure 2 is a face View of a guardrring used therein;

Figures 3 and 4 illustrate steps in the making ci an electrolyte element;

Figure 5 shows a modified electrolyte element;

Figure 6 is a side view of a modified flat cell;

Figures '7 and 8 are top and sectional views of a battery of cells embodying features .of the invention; and l Figure 9 shows a modied battery.

The preferred gel electrolyte for the cellslof the present invention comprises an Vaqueous alkali metal hydroxide solution which is gelled with an alkali metal salt of carboxymethylcellulose, such as sodium carboxymethylcellulose. Sodium carboxymethylcellulose is a rcellulose derivative that is readily soluble or dispersible in' water, and is supplied by Hercules Powder Co., Wilmington, Delaware, as a white granular powder.

It is also contemplated, for long shelf life under adverse temperature conditions, that the electrolyte may, in some cases, contain a substantial proportion of dissolved alkali metal zincate.

' One suitable electrolyte is formed of.:

Chemically pure lpotassium hydroxide (88% KOH) grams 100 Zinc oxide do 16 Water r`nl.. 100

The sodium carboxymethylcellulose is added to the electrolyte in proportions of 6 grams per 100 ml. of solution. In preparing the electrolyte the potassium hydroxide is added to 25 ml. of water and the zin-c oxide added. The mixture is stirred and heated to 180490 C. and then allowed to cool to 110 C.. after which 25 ml. of wateris added and the solution stirred and cooled to C. The remaining 50 ml. of water is'added, a clear solution being obtained. The `'.sodi'um'carboxymethylcellulose is crushed and screened through -a 40 mesh screen and isradded slowly .to the Solution, with `constant stirring. This forms a mushy suspension which can be converted to a gel by heating to a temperature slightly'below the boiling point of the mixture (about 117120 C.) at which point a'clear liquid solution is 4olotained which, upon cooling;.will form a clear, homogeneous, self-supporting gel. It is' necessary to heat the solution to within 5 degrees of its boiling point to obtainva'jcl'ear solution which will give a clear gel on cooling.

Figure 1 is a diametral section througha cir cular fiat cell. This cell comprises an' anode formed of a shallow zinc cup 40 having'fa'n out# wardly flared ange 4I at its edge anda layer 62 of amalgamated yzinc shot compressed in the bottom of the cup'. Y

The zinc shot is of graduated sizes all of which pass through av 28 mesh screen. nIt is l amale gamated with liquid mercury' (90 grams zinc to 10 grams mercury) under a 15% ammonium hy` droxide solution. The mixture is stirred or tumbled in a bottle until the mercury is well distributed after which the zinc is washed with water, vacuum dried at 80'D C. and'pressed into the cup-40. I have found the ainalgainatedlzino shot or pellet anode to be freer from any tendency to gas generation in contact'with alkaline elec'- trolytes than pressedamalgamated zinc powders. On the other hand, it presentsad'equate surface area and sulii'cientlyv sinall particle size to be completely consumed during cell operation, even in electrolytes which are initially saturated with potassium zincato.

While I prefer to 'use the shot in 'the forni of small round particles oit the desired mesh size, other pellet shapes 'freeof the numerous irregular pointed surfaces characteristic ofzinc powder, may be used. For instance, oval or cylindrical pellets of suitable mesh size having rundeds'u'r'- faces and substantially'free of sharp points may be used. In some cases the cup 40' may" be vtorined of a metal or alloy inert to the electrolyte. In order to avoid generation of gas 'after the lepolaizer has been consumed, it is desirable to balance the quantity of zinc in the anode to the depolarizing capacity of the cathode.

Electrolyte layer 43, formed of a disc oi the thick gel previously described, is laid on top of the layer 42. A molded grommet cup 44 oi a plastic such as inert vinyl chloride or styrenebutadene composition or rubber is tted over the bottom free edge of cup 49. The cup 44 has a brass rivet or closed eyelet 52 crimped in a hole in its bottom wall to serve asa contact with the zinc cup 4B. i l 'f A ring 45 (see Figure 2) of relatively impervious sheet material, such as polystyrene lm, parchment paper, regenerated cellulose iilm or polyvinyl alcohol lm is laid on the upper face'A of the grommet and electrolyte disc. .aV 5 mil thick ring of clear polystyrene lm ismost suit` able. This ring extends from the outer iedge of Y the grommet in over the edge of electrolyte disc 43 for a distance of l0 to 30% of the radius of` the disc, and seals itself to the surface of the electrolyte disc. i

The cathode member is compressed in the bottom of a shallow'cup 4t of'ierrous metal such as iron orssteel, whoseedge is formed with a flange having a flat circular portion 4l and a cylindrical portion'48 capable of tting over the outer. periphery of. grommet'44. "A layer 49 oi the cathode-depolarizer composition is pressed into cup 46 to the level ofllange portion 41. The

preferred composition isiormed of finely divided mercuric oxide intimately mixed with 5% of micronized graphite. 2 1:, L

The cathode-depolarzer layer .V44 is pre-impregnatedwith liquid electrolyte .before assembly. This electrolyte may.- be Lof the composition f previously described, omittingVr the .,gelling agent.

The assembly is completed Vbyplacingthe cathode member down over ;th'e.anodeel'ectrolyte assembly and spinningin the edge 59 of iiange 48 to compress the grommet and seal the cell. The

spacingV between anode-and cathode is slightly less than the original thickness of electrolytev gel disc 43 sorthat pressure-i is applied thereto.

. The portion 4l of the flange. on cup' is pro vided with four small holes 5l spaced .90 .degrees apart. In event of any substantial gas pressure within the cell the pressurewill cause a slight opening of theioint` betweenV flange 4'! and ring 45 permitting ready escape of gas through holes 5l. v

One practical cell of the construction shown in Figure 1 had a cathode 120 mils thick, va .gel electrolyte layer 100 milsrthick and a pressed zinc shot anode mils thick. YThe gel disc was 975 mils in diameter.V ,A

A smaller cell had a cathode 80 mils thick, a gel disc 85 mils thick. and 445 mils in diameter, and a zinc shot anode 35 mils thick.

The grommet cup 44 affords protection against electrolyte leakage at theend of cell life. When the cell reaches the end offits life the wall of zinc cup 40 is considerablyv weakened, dueto the electrolyte action, and brittle due to amalgamation with mercury from the anode layer 42. In this condition it will in some lcases break or crack due to internal or external forces. x When this occurs the plastic cup 44 will retain the cell intact and prevent any leakage of electrolyte Yor other cell materials.`

Where mercurio oxide is used as the depolarzer material operation of the cell will result in av progressive reduction of the oxide and forma' '4 lyte disc 43 due to consumption of water. Ring 45 prevents the liquid mercury from running down around the edge of the electrolyte disc under these conditions since it extends in over the edge of the electrolyte disc by an amount which is greater than any shrinkage the disc will undergo. With other depolarizer materials the ring 45 will not always be necessary, although it is preferably used to prevent small leakagecurrents through zinc oxide which might Aform on the edge of thegel disc. The ring 45 is also of advantage in cells using paper spacers impregnated with electrolyte, particularly with mercurio oxide cathodes.

Figure 3 and 4 illustrate a method of making electrolyte discs 43. The clear solution 60 of hot liquid electrolyte containing the gelling agent (such 1 as sodium carboxymethylcellulose) is poured from the beaker 59 into a two part mold el comprising spaced parallel plates 62 and 63, where it gels into a flat sheet 64. After cooling the stili gel sheet 64 is removed from the mold and discs 43 are punched from it.

Figure 5 shows a modified electrolyte disc 53 which comprises a disc of porous absorbent sheet material impregnated with the gel electrolyte. The preferredabsorbent material is a pure felted cotton 'fibre paper, such as Feltril paper, about 60 mils thick. The paper. is vacuum impregnated with the unheated and ungelled electrolyte solution or mixture by placing in the solution and applying a vacuum above the solution to draw out air bubbles and then is placed between spaced stainless steel plates and heated to about 120 C. after which it is cooled until thegel has hardened. It is then removed andv discs 53 are punched from the sheet.

While mercurio oxide has been described as the depolarizer material, other suitable depolarizers may be used. v

While zinc shot is preferred for the anode it is also possible to use other forms of zinc anode member of large surface area, such as a porous pressed body of amalgamated zinc powder or other porous zincbody.

The potassium hydroxide in the electrolyte may vary in concentration, the most useful range extending from 39 to 54% KOH. The proportion of sodium oarboxymethylcellulose can vary, the range between 3 and 12- grams per 100 ml. of electrolyte being most suitable. With proportions of potassium hydroxide below grams per ml. of water (39% KOH) the electrolyte does not appear to form a homogeneous clear gel with the sodium carboxymethylcellulose, probably due to freer'water. Heating of the electrolyte mixture substantially to the boiling point is also essential to obtaining a clear homogeneous gel;

For maximum shelf life under elevated tem perature conditions the electrolyte is given a preliminary content of potassium zincate by dissolving zinc oxide in the solution. The amount of zincato, calculated as zinc, preferably amounts to between 14 and 29 grams of Zinc for each 100 grams of potassium present as potassium hydroxide and potassium zincate. Part of the potasslum hydroxide originally used is converted to potassium zincate by reaction with the zinc oxide so that the percentage of KOH present as such in the solution is reduced. However, the titratable quantity of potassium hydroxide remains' the same due to the reversibility of the reaction with the Zinc oxide.

As the zinc anode is converted to zinc hydroxacoaee'i ide during operation-the thickness of theanode increases. This is compensated for, however, in the structure of the present invention by a progressive decrease in the thickness of thegel electrolyte layer due to withdrawal of'moisture tothe anode. Hence, thetotal thickness and internal pressure of the 'cell assembly"` remains substantially unchanged throughout operation.

The body of` self-sustaining, non-owingelectrolyte gel ydescribed herein not only performsthe usual function of cell electrolyte in undergoing electrochemical reaction With the electrodes and providing an electrolytically conductive path between them, but also functions as a mechanical spacer andas a barrier to the travel of deleteriousyccmpounds, graphit-e particles and reaction productsfrom cathode to anode. The electrolyte being immobilized into a Vgel has no free circulation which would carry compounds from one electrode to the other. A

A'paper or nbre disc can also be impregnated with the hydroxide gel to form an element 53 (Figure 5). In this event less gelling agent may be required, for example 2 grams of sodium carboxymethylcellulose per 100 milliliters of solution.

Other gelling agents which can be used are starch and methyl cellulose.

Figure 6 is a sideview of a small cell 'i having a similar internal construction to that of Figure l. The cell container comprises a steel cup li, a zinc cup 'i2 and a synthetic rubber grommet 73. In this oase, however;-the grommet does not extend Vover the bottom of the zinc cup but leaves the zinc bottom exposed.

Figures '7 and 8 show a battery formed of such cells. The battery comprises two stacks of six cells each, the left hand stack having all the zinc negative terminals facing downward and the right hand stack having the zinc terminals facing upward. The cells are clamped between a top phono-formaldehyde plastic plate 88 and a bottom metal plate 8i. The metal plate electrically connects the two cell stacks together in series. Below metal plate 8i isa layer of resilient material 82, such as sponge rubber and below this is an insulating plate 8S. The entire assembly is clamped together under pressure by a tie wire Sli. Insulating plate 8B is provided with a pair of battery terminals comprising rivets 85 and 86 passing through the plate into contact with the top cells of the stacks, and U-shaped contact springs S7 andA 88 for connecting the battery to a load circuit.

A partition 83 of insulating sheet plastic is nterposed between the two stacks to prevent accidental short circuiting and a plastic sheath 96 encloses the sides of the assembly and is turned over the ends. The sheath may suitably be formed of vinyl polymer resins, such as Vinylite, or of a viscose film. One method of applying a vinyl resin iilm sheath is as follows: A tube of Vinylite of smaller diameter than will encircle the battery is softened in hot water and then stretched on a form larger than the battery. It is chilled in cold water in the stretched condition after which the form is removed from vthe expanded tube, which retainsits large size. The tube is dried and then slipped over the battery. As it warms up the tube will shrink tightly over the battery into the position illustrated.

The resilient layer 82 of sponge rubber applies uniform pressure to the stack of cells and can take up any swelling of the cells at the end of their life or at any other time.

Figurel 9":shows a modified battery havingone terminal .at each end. In this battery both stacks of cells are arranged with the zinc negative terminals at the bottom. An insulating plate IBI is Aprovided in place 'of a metal plate between the cells and the resilient layer |82. A conductor i 18 connects the stacks together in series. A secuondcor'iductor H Qrconnects the end of theright Ahand stack to a .metal plate |83 forming the bottom of the battery. linsulating Vplate yI8!) forming the top of the battery has a singleterini-'nal |871 "thereon connected to the top. of the left yhand stack. y Whatl Vi's'olaimed Y Y 1. An electric current producing cell comprising a-pair of dished-metal` members respectively having inner and outer interiitting -marginal regions each of which includes a portion extending-substantially radially anda portion extending substantially axially of the cell, such portions of one metal member being substantially parallelspaced from the corresponding-portions of the other memben'and an annular insulative sealing grommetalso having a substantially radially and a. substantially axially'extending portion which portions are compressed between the correspondingrportions ofjsaid metal members, the marginal region of the outer dished member being radially crimped inwardly at a level below the' plane deiiningthe innerspacepof one member from that of the'fother thereby maintaining the radially extending portion ofthe grommet' under sealing compression in the Aaxial direction and the axially extending portion of the grommet under sealing a compression in the radial direction.

V2. vAn electric current producing cell comprising a pair of dished metal terminal members respectively having inner and outer intertting marginal regions each of which includes a por'- tion extending vsubstantially, radially and 'avr portion extending substantially axially of 'the cell, suchportions ofone .metal memberbeing substantially parallel-spaced from the corresponding portions of the othermember, astructurally distinct anode within vand in pressure contact with one. of said members, a structurally distinct cathode within and in .pressure contact with the other of said members, and an annular insulative ksealing Ygrommet also. having a substantially radially and a substantially axially extending portion which portionsare compressed between the corresponding portions of said metal members', the marginalregion of theouter dished member being radially crimped inwardly at a f level below the plane defining'the inner space of one dished memberfrom that oi the other thereby maintaining the radially extending portion-of the grommet under sealing compression in the axial direction and the axially extending portion of the grominet under sealing compression in the radial direction.

' 3f An electric current producing cell comprising a pair of structurally independent metal compartments having interltting marginal regions nested ineach other, each of said regions including a portion extending substantially radially and a portion extending substantially axially of the cell, such portions ofone metal compartmentbeing substantially parallel-spaced from the corresponding portions of the other compartment, a cathode depolarizer pressed into and consolidated with one of said compartments,

an anode pressed into and consolidated with the other of said compartments, an immobilized electrolyte interposed between and in contact with said cathode and anode, and an insulative sealing grommet around the marginal region of one of said compartments also having a substantially radially and "a substantially axially extending portion which portions are compressed between the corresponding portions of the compartments, the marginal region of the other compartment being radially crimped inwardly at a level below the plane defining the inner space of one compartment from that of the other thereby maintaining the radially extending portion of the grommet under sealing compression in the axial direction and the axially extending portion of the grommet under sealing compression in the radial direction.

4.7An electric current producing cell comprising a pair of structurally independent metal compartments having intertting marginal regions nested in each other, one of said compartments being formed of steel, eachof said marginal regions of the compartments including a portion extending substantially radially and a portion extending substantially axially of the cell, such portions of one compartment being substantially parallel-spaced from the corresponding portions of the other compartment, a structurally distinct cathode within and in pressure contact with said steel compartment, a structurally distinct zinc anode within and in pressure contact with the other compartment, an immobilized electroly-te between said cathode and anode, and an annular insulative sealing grommet mounted around the marginal region of one of said compartments also having a substantially radially and a substantially axially extending portion whichV portions are compressed between the corresponding portions of the compartments, the marginal region of the other compartment being radially crimped inwardly at a level below the plane dening the inner space of one compartment from that of the other thereby maintaining the radially extending portion of the grommet under sealing compression in the axial direction and the axially extending` portion of the grommet under sealing compression in the radial direction.

5. An electric current producing cell compris ing a steel compartment,v a cathode depolarizer including mercurio oxide pressedinto said compartment to form low resistance contact therewith, a second metal compartment, a structurally distinct zinc anode within and in pressure contact with said second compartment, said compartments respectively constituting the positive and negative terminals of the cell and having interfltting marginal regions nested in each other, each of said marginal regions including a portion extending substantially radially and a. portion extending substantially axially of the cell, such portions of one compartment being substantially parallel-spaced from the corresponding portions of the other compartment, an immobilized electrolyte between and in contact with said cathode and anode, and an annular insulative sealing grommet mounted around the marginal region of one of said compartments also having a substantially radially and a substantially axially extending portion which portions are compressed between the corresponding portions of the compartments, the marginal region of the other compartment being radially crimped inwardly at a level below the plane defining the inner space of one compartment from that of the other thereby maintaining the radially extending portion of the grommet under sealing compression in the axial direction and the axially extending portion'of the grommet under sealing compression in the radial direction.

6. An electric current producing cell comprising a pair of metal cups respectively having inner and outer circumferential marginal regions nested in each other, each of said marginal regions including a portion extending substantially radially and a portion extending substantially axially of the cell, such portions of one cup being substantially parallel-spaced from the corresponding portions of the other cup, and a generally L-shaped insulative sealing grommet around the inner marginal region of the corresponding cup also having a substantially radially and a substantially axially extending portion which 'portions are compressed between the corresponding portions of the cups, the marginal region of the other compartment being radially crimped inwardly at a level below the plane defining the inner space of one compartment from that of the other thereby maintaining 'the radially extending portion of the grommet under sealing compression in the axial direction and the axially extending portion of the grommet under sea-ling compression in the radial direction.

SAMUEL RUBEN.

nnrnnnnons orrnn The following references are of record in the ille of this patent:

UNITED STATES PATENTS Number Name Date Re. 14,929 Baumann Aug. 17, 1920 373,064 Gassner NOV. 15, 1887 408,138 Schoop July 30, 1889 413,438 Eggers Oct. 22. 1889 503,415 Garbarro Aug. l5, 1893 680,848 Erny Aug. 20, 1901 1,137,226 Manchester Apr. 27, 1915 1,219,074 Bronsted Mar. 13, 1917 1,500,027 Morch July 1, 1924 1,611,153 Benner et al. Dec. 21, 1926 1,997,367 Killian Apr. 9, 1935 2,174,437 Collins Sept. 26, 1939 2,307,766 Deibel Jan, 12, 1943 2,399,089 Anthony Apr. 23. 1946 2,509,249 Rhodes May 30, 1950 FOREIGN PATENTS Number Country Date 15,471 Great Britain 1915 60,860 Germany Nov. 25, 1890 129,423 Great Britain July 8, 1919 224,484 Switzerland Mar. l, 1943 380,707 France Oct. 17, 1907 513,744 France Nov. 5, 1920 OTHER REFERENCES Ser. No. 394,417. Marhenkel (A.P.C.), published May 11, 1943.

Abstract of application 603,739 of Nye, published October 11, 1949.

Hollabaugh et al.: Industrial and Engineering Chemistry, pages 943 and 944, October 1945. 

